METHOD OF PRODUCING A REINFORCEMENT ELEMENT

Abstract

A method of producing a reinforcement element for reinforcing a structural element in a motor vehicle includes the following steps: pultruding a support element having a longitudinal axis that extends, when in use, along a longitudinal axis of the structural element, the support element having a plurality of outer faces that extend in the direction of the longitudinal axis; placing an adhesive on at least one of the outer faces of the support element; and cutting the pultruded support element to size

Claims

1. A method for producing a reinforcing element for reinforcing a structural element in a motor vehicle, the method comprising the following steps: pultruding a carrier element, which has a longitudinal axis extending along a longitudinal axis of the structural element in a use state, wherein the carrier element has multiple outer surfaces extending in the direction of the longitudinal axis; arranging an adhesive on at least one outer surface of the carrier clement element; and cutting the pultruded carrier element to length.

2. The method as claimed in claim 1, wherein the adhesive is a shape memory material.

3. The method as claimed in claim 2, wherein the method comprises the following further step: pressing the adhesive to transfer the adhesive into a stressed state.

4. The method as claimed in claim 2, wherein the adhesive is arranged on the carrier element before the carrier element is cut to length, and/or wherein the adhesive is pressed before the carrier element is cut to length.

5. The method as claimed in claim 3, wherein the adhesive is pressed by a roller.

6. The method as claimed in claim 1, wherein the method comprises the following further step: extruding or overmolding an additional element onto the carrier element.

7. The method as claimed in claim 6, wherein the additional element is extruded or overmolded onto the carrier element through a nozzle integrated in a production line, before the pultruded carrier element is cut to length (in-line process).

8. The method as claimed in claim 6, wherein the additional element is extruded or overmolded onto the carrier element by a downstream station, after the pultruded carrier element is cut to length.

9. The method as claimed in claim 6, wherein the additional element is in the form of ribs, which extend substantially transversely with respect to the longitudinal axis of the carrier element and which increase the torsional rigidity and/or the flexural rigidity of the carrier element.

10. The method as claimed in claim 6, wherein the additional element is in the form of at least one wall on at least one outer surface of the carrier element, wherein the wall delimits the adhesive in at least one direction on the outer surface.

11. The method as claimed in claim 6, wherein the additional element is in the form of at least one spacer element, which is in contact with the structural element, and thus defines a position of the reinforcing element relative to the structural element in at least one direction, in a use state of the reinforcing element.

12. The method as claimed in claim 6, wherein the additional element is extruded or overmolded onto the carrier element in multiple method steps and/or through multiple nozzles.

13. The method as claimed in claim 6, wherein the additional element comprises polyamide.

14. The method as claimed in claim 6, wherein the additional element is extruded or injection molded around the carrier element, with the result that the additional element is aligned substantially transversely with respect to the longitudinal axis of the carrier element.

15. The method as claimed in claim 6, wherein the method comprises the following additional step: extruding or overmolding a second additional element onto the carrier element and/or onto the first additional clement element.

Description

[0060] Details and advantages of the invention will be described below on the basis of exemplary embodiments and with reference to schematic drawings, in which:

[0061] FIG. 1A shows an exemplary illustration of a pultrusion method;

[0062] FIG. 1B shows an exemplary illustration of further stations in a pultrusion production line;

[0063] FIG. 1C shows an exemplary illustration of downstream stations;

[0064] FIG. 2 shows an exemplary illustration of a reinforcing element illustrated in three dimensions;

[0065] FIG. 3A to 3C show exemplary illustrations of cross sections through reinforcing elements; and

[0066] FIGS. 4 and 5 show exemplary illustrations of reinforcing elements illustrated in three dimensions.

[0067] FIG. 1A to 1C illustrate an exemplary method for producing a reinforcing element. In this respect, FIG. 1A shows an overview of such a method, and FIG. 1b and 1C show further details of phases of this production method. In this respect, FIG. 1B schematically illustrates a phase within the production line with further stations, and FIG. 1C illustrates downstream stations that are not located in the primary production line of the pultrusion method.

[0068] According to FIG. 1A, in the course of the pultrusion, fibers 2 from fiber holding creels 1 first of all are guided through a resin tank 3. The profile 10 is then shaped and hardened in a hardening tool 4. A drawing tool 5 ensures that the fibers 2 are arranged under tension during these process steps. Accordingly, these steps result in the production of a profile 10 which serves as starting point for the carrier element. Lastly, a cutting-to-length station 6 subdivides the endlessly produced profile 10 into cut-to-length elements 7.

[0069] FIG. 1B schematically illustrates stations within the production line that are arranged in phase 8 in the overview according to FIG. 1A. In the exemplary embodiment, what is illustrated first of all is an adhesive application station 21. At this station, an adhesive is arranged onto the pultruded profile 10. In this exemplary embodiment, a shape memory material is used as adhesive. Furthermore, the adhesive is pressed by rollers 18 at a pressing station 22 and transferred into a stressed state. In addition, in this exemplary embodiment there is an extrusion station 23, from which an additional element can be extruded onto the profile 10 or the carrier element using a nozzle 29.

[0070] FIG. 1C schematically illustrates downstream stations that are arranged in phase 9 in the overview according to FIG. 1A. In this exemplary embodiment, there is a first downstream station 24, a second downstream station 25, and a third downstream station 26. What these downstream stations 24, 25, 26 have in common is that there is always a respective production step being performed there on a cut-to-length element 7 of the pultruded profile 10. For example, a first additional element can be extruded or overmolded onto the carrier element at the first downstream station 24. In the second downstream station 25, it is possible, for example, for the adhesive to be arranged on at least one outer surface of the carrier element. And in the third downstream station 26, it is possible, for example, for a second additional element to be extruded or overmolded onto the carrier element and/or onto the first additional element.

[0071] In order to produce a reinforcing element from the pultruded profile 10, it is possible, for example, for work to be done only with stations in the production line, or else work can be done only with downstream stations, or else work can be done both with stations in the production line and with downstream stations.

[0072] FIGS. 2 to 5 then illustrate, schematically and by way of example, reinforcing elements 16 that can be produced by a method according to FIG. 1A to 1C.

[0073] FIG. 2 schematically illustrates a reinforcing element 16 by way of example. The reinforcing element 16 has a carrier element 11 that has a longitudinal axis 15. The carrier element 11 has multiple outer surfaces 17 extending in the direction of the longitudinal axis 15. An adhesive 13 is arranged on these outer surfaces 17. In this exemplary embodiment, the reinforcing element 16 does not have any further additional elements, such as ribs or walls or spacer elements.

[0074] FIG. 3A to 3C schematically illustrate cross sections through exemplary reinforcing elements 16.

[0075] FIG. 3A illustrates a reinforcing element 16 with a trapezoidal cross section. The carrier element 11 has a respective adhesive 13, laterally terminated by walls 14, arranged on three outer surfaces. Such walls 14 are therefore advantageous, because on the one hand they protect the adhesive 13 against mechanical influences, and on the other hand they can ensure expansion of the adhesive 13 or dimensional stability of the adhesive 13 when the adhesive 13 is activated.

[0076] FIG. 3B schematically illustrates a further cross section of a further exemplary reinforcing element 16. In this exemplary embodiment, the carrier 11 has a rectangular cross section. In this exemplary embodiment, an expandable material 19 and an adhesive 13 arranged thereon is arranged on the two broader outer surfaces 17 of the carrier element 11. In this respect, the expandable material 19 and the adhesive 13 are in turn laterally terminated by walls 14. When the expandable material 19 and the adhesive 13 are activated, the adhesive 13 is pressed against an inner side of the structural element by the expansion of the expandable material 19.

[0077] FIG. 3C schematically illustrates a further exemplary cross section of a reinforcing element 16. In this exemplary embodiment, the carrier element 11 has an M-shaped, or

[0078] W-shaped, cross section. A respective adhesive element 13 is arranged on four outer surfaces. In addition, this reinforcing element 16 has spacer elements 18, which define a spacing between the carrier element 11 and the structural element (not illustrated) in a use state of the reinforcing element 16.

[0079] FIG. 4 schematically shows an exemplary reinforcing element 16 illustrated in three dimensions. In this respect, the carrier element 11 has a substantially U-shaped cross section, and adhesive 13 is arranged on outer surfaces 17 of the carrier element. In this exemplary embodiment, the reinforcing element has additional elements in the form of ribs 12, which run transversely with respect to the longitudinal direction of the carrier element 11. Providing such ribs 12 increases the torsional rigidity and/or the flexural rigidity of the carrier element.

[0080] FIG. 5 now schematically shows a reinforcing element 16 illustrated in three dimensions. In this exemplary embodiment, the carrier element 11 has a rectangular cross section. An adhesive 13 is arranged on an outer surface 17 of the carrier element 11. In this exemplary embodiment, the adhesive 13 is delimited on all sides by walls 14.

LIST OF REFERENCE SIGNS

[0081] 1 Fiber holding creel

[0082] 2 Fiber

[0083] 3 Resin tank

[0084] 4 Hardening tool

[0085] 5 Drawing tool

[0086] 6 Cutting-to-length station

[0087] 7 Cut-to-length element

[0088] 8 Phase with stations in the production line

[0089] 9 Phase with downstream stations

[0090] 10 Endless profile

[0091] 11 Carrier element

[0092] 12 Rib

[0093] 13 Adhesive

[0094] 14 Wall

[0095] 15 Longitudinal axis

[0096] 16 Reinforcing element

[0097] 17 Outer surface

[0098] 18 Spacer element

[0099] 19 Expandable material

[0100] 21 Adhesive application station

[0101] 22 Pressing station

[0102] 23 Extrusion station

[0103] 24 First downstream station

[0104] 25 Second downstream station

[0105] 26 Third downstream station

[0106] 28 Roller

[0107] 29 Nozzle